Structural element

ABSTRACT

A structural element including a substantially flat central portion, a first web portion perpendicularly extending from an edge of the central portion, and a second web portion perpendicularly extending from an opposing edge of the central portion. The central portion and the first and second web portions are formed from a unitary steel sheet. The structural element is suitable for forming load bearing floors and/or walls in a structure.

FIELD OF THE INVENTION

The present invention relates to the field of structural units, and more particularly to the field of fast erection light structural units.

BACKGROUND OF THE INVENTION

Structural units are known. They vary in the constructional materials they are made from, and, in the erection methods. The most common structures are made of concrete with reinforcing steel. These structures are very strong, however, they are very heavy, expensive, and require relatively long erection period; preparation of molds, long curing periods of the concrete, laboratory tests for verifying final strength, etc.

Other structural units are made of a massive steel frame that may be erected by welding or bolting. A light cover, made of a variety of materials is then assembled on the steel frame. The light cover may consist of an aluminum frame onto which are assembled glass plates, gypsum plates, and the like.

There are also known and common wooden structural units. These units are known for their fast erection time and ease of construction. However, these units require construction of a wooden “frame”, including large and massive wooden logs and wooden bars. Upon finishing the construction of the frame, a “cover” is put on the “frame”.

It is the purpose of the present invention to provide a structural element for building a structural unit that significantly reduces or overcomes the aforementioned disadvantages.

It is another purpose of the present invention to provide a structural element for building a structural unit that may be erected in a fast manner and is cheap and light.

It is also a purpose of the present invention to provide a structural element for building a light and fast erected structural unit that may be built to several stories high, typically, up to five stories high.

It is yet another purpose of the present invention to provide a structural element for building a structural unit wherein the structural element provides both the frame and the cover of the unit.

SUMMARY OF THE INVENTION

A structural unit is formed from structural elements that are connected to each other in a simple manner. When all the structural elements are attached to each other, the structural unit may form a strong and rigid structure up to five stories high.

The advantage of the structural element of the present invention is that construction of a structural unit with a separate frame onto which a cover is assembled is successfully prevented. Thus, the structural unit includes both a frame and a cover formed using the structural element of the present invention.

There is provided, in accordance with an embodiment of the present invention, a structural element including a substantially flat central portion, a first web portion perpendicularly extending from an edge of the central portion, and a second web portion perpendicularly extending from an opposing edge of the central portion. The central portion and the first and second web portions are formed from a unitary steel sheet. The structural element is suitable for forming load bearing floors and/or walls in a structure.

In some embodiments, the first and second web portions include a flat portion and at least one longitudinally extending ridge.

In some embodiments, the flat central portion includes one or more longitudinally extending ridges.

In some embodiments, the first and second web portions include an inwardly directed end bend directed in a direction towards the central portion.

In some embodiments, the first and second web portions include an outwardly directed end bend directed in a direction away from the central portion.

In some embodiments, the first web portion includes an inwardly directed end bend directed in a direction towards the central portion and the second web portion includes an outwardly directed end bend directed in a direction away from the central portion.

In some embodiments, the at least one longitudinally extending ridge is inwardly directed in a direction towards the central portion.

In some embodiments, the at least one longitudinally extending ridge is outwardly directed in a direction away from the central portion.

There is provided, in accordance with an embodiment of the present invention, a structural unit formed from a plurality of structural elements, each structural element having a substantially flat central portion, a first web portion perpendicularly extending from an edge of the central portion, and a second web portion perpendicularly extending from an opposing edge of the central portion. The central portion and the first and second web portions are formed from a unitary steel sheet. The structural element is suitable for forming load bearing floors and/or walls in a structure. Also included is a ground slab to support the structure.

In some embodiments, the first and second web portions in each of the structural elements include a flat portion and at least one longitudinally extending ridge.

In some embodiments, the structure includes a frame formed using the structural elements.

In some embodiments, the structure includes one or more floors formed using the structural elements.

In some embodiments, the structure includes one or more walls formed using the structural elements.

In some embodiments, the structure includes a maximum of five stories.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention and to show how the same may be carried out in practice, reference will now be made to the accompanying drawings, in which:

FIG. 1 is a perspective view of a structural unit built using structural elements, according to an embodiment of the present invention;

FIG. 2 is a perspective view of a structural element, according to an embodiment of the present invention;

FIG. 3 is a cross-sectional view showing the connection between the web portions of two consecutive structural elements, according to a first embodiment of the present invention;

FIG. 4 is a cross-sectional view showing the connection between the web portions of two consecutive structural elements according to a second embodiment of the present invention;

FIG. 5 schematically illustrates the construction of the balcony in the structural unit, according to an embodiment of the present invention;

FIG. 6 schematically illustrates the construction of a wall in the structural unit, according to an embodiment of the present invention;

FIG. 7 schematically illustrates the construction of a façade and roof in the structural unit, according to an embodiment of the present invention;

FIG. 8 schematically illustrates the construction of an internal floor and walls in the structural unit, according to an embodiment of the present invention;

FIG. 9 schematically illustrates the construction of a floor and a wall (interior and/or exterior) in the structural unit, according to an embodiment of the present invention; and

FIG. 10 schematically illustrates the construction of a floor (ledge) and exterior wall in the structural unit, according to an embodiment of the present invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

Attention is drawn to FIGS. 1 to 4 that show a structural unit 10 according to the present invention. For a matter of simplicity, the structural unit 10 will hereinafter be called “unit”.

It should be noted that directional terms appearing throughout the specification and claims, e.g. “forward”, “rear”, “upper”, “lower” etc., are used as terms of convenience to distinguish the location of various surfaces relative to each other. These terms are defined with reference to the figures, however, they are used for illustrative purposes only, and are not intended to limit the scope of the invention.

The unit 10 is formed from a plurality of structural elements 12 that make up the major portion of the unit 10. Each of the structural elements 12 is produced out of a steel roll, having a given width, which is rolled and cut to the desired shape and length.

Each of the structural elements 12 is formed from a unitary piece that comprises a central portion 14 and two web portions 16 extending perpendicularly therefrom. The structural element 12 has an element length L and an element width W. Typically, each of the web portions 16 comprises a flat web portion 18 and a longitudinally extending ridge 20 that increases the rigidity of the web portion 16 and hence of the entire structural element 12. If desired, and depending on the use, also the central portion 14 may be provided with a ridge, or a plurality of ridges, for increasing the total rigidity and bending resistance of the structural element 12.

If desired, and depending on the use, the free end of each of the web portions 16 is provided with an inwardly directed end bend 22. The end bend 22 significantly increases the rigidity of the web portions 16 and hence of the entire structural element 12. Furthermore, the end bend 22 adds additional convenience and safety when transporting, conveying and using the structural element 12.

In some embodiments, as shown in FIGS. 2 and 3, the ridges 20 of the web portions 16 are inwardly directed, thus enabling easy abutment of the flat web portion 18 of a given structural element 12 against the flat web portion 18 of the consecutive structural element 12. The web portions 16 are then attached to each other by a multitude of self-drilling screws 24. After the first alignment of two consecutive structural elements 12, the application of the self-drilling screws 24 is easy, fast, and does not require any specific accuracy. Thus, after the application of the multitude of self-drilling screws, the two structural elements 12 are rigidly attached to each other and form a single unit.

In other embodiments, as shown in FIG. 4, the web portions 16 are formed such that a first web portion of a given structural element is formed with the ridge directed inwardly, while a second web portion of the same structural element is formed with the ridge directed outwardly. Thus, as shown in FIG. 4, when a web portion of a structural element is put adjacent a web portion of a consecutive structural element, the two ridges fit into each other in a male-female manner, thus providing additional fit and sturdiness between the structural elements. It is clear in this case, that the male ridge should be slightly smaller than the female ridge in order to provide perfect fit therebetween.

In order to form the structural unit 10, as seen in FIG. 1, a multitude of structural elements 12 are attached to each other as described above and placed vertically on a pre-prepared base foundation. The base foundation may be formed from gravel or concrete to suit the floor tiling that will be later applied thereon.

Upon finishing connecting the vertically standing structural elements 12, an upper horizontal structural element 12 is placed thereon and connected therewith by means of corner L-beams that are attached by self-drilling screws. Other type of attachment means may be used to connect the vertical and horizontal structural elements 12 and may include structural components such as beams and profiles (U-shaped, T-shaped, I-shaped, T-shaped, etc.) known in the art. FIGS. 5 to 9 schematically illustrate exemplary connections of the structural elements 12 used to build the structural unit 10, according to some embodiments of the present invention. Appropriate structural attachment elements are used to connect the structural elements 12 with other structural components.

FIG. 5, for example, illustrates the construction of the balcony in the structural unit 10 (detail B) and includes multiple structural elements 12 horizontally and vertically arranged. Horizontal structural elements 12 are laid over a horizontal beam 13 which is supported on one side by a column 17 and on the other side by a vertical structural element 12 which also forms the exterior wall of the unit 10. The horizontal structural elements 12 support a balcony deck structure 15.

FIG. 6, for example, illustrates the construction of a wall in the structural unit 10 (detail A) and includes vertical structural elements 12 attached to a floor 19 in one of the stories. The vertical structural elements 12 may be covered by blocks or other type of coverings (e.g. gypsum boards, metal lathe and plaster, among other known covering).

FIG. 7, for example, illustrates the construction of a façade and roof in the structural unit 10 (detail D) and includes multiple structural elements 12 vertically and horizontally arranged. As may be appreciated from the figure, the horizontal structural elements 12 are supported at the ends by vertical structural elements 12 which also form a section of the façade of the structure 10. The horizontal elements 12 support the roof structure 23.

FIG. 8, for example, illustrates the construction of an internal floor and walls in the structural unit 10 (detail E) and includes multiple structural elements 12 vertically and horizontally arranged. As may be appreciated from the figure, the horizontal structural elements 12 form the floor and are supported by the vertical structural elements 12 which form the walls.

FIG. 9, for example, illustrates the construction of a floor and a wall (interior and/or exterior) in the structural unit 10 (detail F) and includes multiple structural elements 12 vertically and horizontally arranged. As may be appreciated from the figure, the horizontal structural elements 12 form the floor and are supported by the vertical structural elements 12 which form the walls. The horizontal structural elements 12 on one side of the wall may be oriented perpendicularly to those on the other side of the wall.

FIG. 10, for example, illustrates the construction of a floor (ledge) and exterior wall in the structural unit 10 (detail C) and includes multiple structural elements 12 vertically and horizontally arranged.

As can be appreciated from the figures, when all the structural elements 12 are connected to each other to form the structural unit 10, the overall strength and rigidity of the structural unit 10 is much stronger than the strength and rigidity of the individual structural elements 12.

This form of building the structural unit 10 has been found to be efficient at least up to five stories height. In that manner, a cheap and fast erecting structure can be built, without the need of concrete columns or steel beams.

The structural unit 10 built according to the present invention enables considerable savings and advantages during the construction process;

-   1. The transportation of prepared structural elements 12 to the     erection site may be prevented. -   2. The structural elements 12 may be rolled and cut on site, thus     saving the transportation of a considerable volume of elements. -   3. The on-site production of the structural elements 12 eliminates     any damages to the structural elements 12 that may otherwise occur     during transportation thereof. -   4. Greater versatility and ability to provide on-site required     amendments of the structural elements 12, e.g., amending their     length, etc. -   5. It is not necessary to prepare molds for concrete casting. -   6. It is not necessary to wait for concrete curing, thus saving a     lot of time and reducing the erection period. -   7. The structural elements 12 provide both the frame and the cover     of the structural unit 10. -   8. It is not necessary to provide large steel beams for supporting     the structural unit 10, thus saving money, time, transportation, and     erection. -   9. The structural unit 10 is erected in a fast and economical     manner, and provides adequate and stable accommodation up to five     stories in height.

Although the present invention has been described to a certain degree of particularity, it should be understood that various alterations and modifications could be made without departing from the spirit or scope of the invention as hereinafter described.

For example, this structural unit may be used for building one, two, or up to five stories high.

The upper cover of the structural unit may be formed from structural elements as described above or similar thereto.

The structural elements may be provided with thermal insulation, as glass wool or the like, and closed by another sheet of metal, to form unit that is covered from its four sides.

Openings in the structural elements, e.g., for doors and windows, may be opened according to design needs.

In some cases, and according to design needs, steel beams may be added to the structural unit. However, these beams are an addition only, and do not form an essential part of the invention. 

What is claimed is:
 1. A structural element comprising: a substantially flat central portion; a first web portion perpendicularly extending from an edge of said central portion; and a second web portion perpendicularly extending from an opposing edge of said central portion; said central portion and said first and second web portions formed from a unitary steel sheet, and wherein the structural element is suitable for forming load bearing floors and/or walls in a structure.
 2. An element according to claim 1 wherein said first and second web portion comprise a flat portion and at least one longitudinally extending ridge.
 3. An element according to claim 1 wherein said flat central portion comprises one or more longitudinally extending ridges.
 4. An element according to claim 1 wherein said first and second web portion comprise an inwardly directed end bend directed in a direction towards the central portion.
 5. An element according to claim 1 wherein said first and second web portion comprise an outwardly directed end bend directed in a direction away from the central portion.
 6. An element according to claim 1 wherein said first web portion comprises an inwardly directed end bend directed in a direction towards the central portion and said second web portion comprises an outwardly directed end bend directed in a direction away from the central portion.
 7. An element according to claim 2 wherein said at least one longitudinally extending ridge is inwardly directed in a direction towards the central portion.
 8. An element according to claim 2 wherein said at least one longitudinally extending ridge is outwardly directed in a direction away from the central portion.
 9. A structural unit comprising: a plurality of structural elements, each structural element of said plurality of structural elements comprising a substantially flat central portion, a first web portion perpendicularly extending from an edge of said central portion, and a second web portion perpendicularly extending from an opposing edge of said central portion, said central portion and said first and second web portions formed from a unitary steel sheet, and wherein the structural element is suitable for forming load bearing floors and/or walls in the structure; and a ground slab to support the structure.
 10. A structural unit according to claim 9 wherein said first and second web portions in each of said structural element comprises a flat portion and at least one longitudinally extending ridge.
 11. A structural unit according to claim 9 further comprising a frame formed using said structural elements.
 12. A structural unit according to claim 9 further comprising one or more floors formed using said structural elements.
 13. A structural unit according to claim 9 further comprising one or more walls formed using said structural elements.
 14. A structural unit according to claim 9 further comprising a maximum of five stories. 